Section 509

Control and Safety Systems

Description

Control and Safety Systems 509.01

Instruments and Automatics 509.05
Lambda Controller 509.10
Starting Box 509.35
Converter for Engine- and Turbocharger RPM Signal 509.40
Working card

Functional Test and Adjustment of Safety, 509-01.00

Alarm and Monitoring Equipment
Functional Test and Adjustment of Overspeed Trip 509-01.05
Adjustment and Test of On/Off Pressostate 509-05.00
Adjustment and Test of On/Off Thermostate 509-05.01
Function and Test of Level Switch (LAL 25) 509-05.02
Adjustment and Test of Analogous Pressure Transmitter 509-05.03
Adjustment and Test of Analogous Temperature Transmitter 509-05.04
Adjustment of lambda Controller 509-10.00

Plates

Overspeed device 50903-02H

Instrument panel 50905-10D
Thermometer 50907-09H
Instruments 50907-10D
Pick-up 50908-10D
Lambda controller 50910-02H
Prelubricating oil alarm (LAL 25) 50919-01H
Level switch in oil sump (LAL/LAH 28) 50920-13H
Fuel oil leakage alarm (LAH 42) 50925-08H
Local starting box - No 2 50935-10D
Terminal box 50936-10D
BLANK
 MAN Diesel

Description 509.01
Page 1 (2) Control and Safety Systems Edition 01H

L23/30H
Governor Should a fuel pump plunger seize in its barrel, thus
blocking the regulating guide, governing of the re-
The engine speed is controlled by a hydraulic go- maining fuel pumps may continue unimpede owing
vernor. The purpose of the governor is to regulate to the spring-loaded linkage between the blocked
the rate of delivery from the fuel pumps, so that the pump and the regulating shaft.
engine speed is kept within certain limits, indepen-
ding on the load.
Stop Screw for Max. Delivery Rate
Information about the design, function and operation
of the governor is found in the special governor The bracket for stop cylinder/limiting cylinder is fitted
instruction book. with a stop screw which prevents the fuel pumps
from being set to a higher delivery rate than what
The governor is mounted on the flywheel end of corresponds to the permissible overload rating.
the engine and is driven from the camshaft via a
cylindrical gear wheel and a set of bevel gears. This is effected by the arm on the regulating shaft
being stopped by the stop screw, see fig. 1.

Pick-up for Engine RPM

Mechanical Overspeed (SSH 81)
The pick-up for transfer of signal to the tachometer
instrument for engine RPM is mounted on the flywheel The engine is protected against overspeeding in the
end cover of the engine. event of, for instance, governor failure by means of
an overspeed trip.
A signal varying proportionally to engine RPM is
created in the pick-up by the rotating toothed im- The engine is equipped with a stopping device
pulse wheel mounted on the camshaft end. which starts to operate if the maximum permissible
revolution number is exceeded.

Pick-up for Turbocharger RPM The overspeed tripping device is fitted to the end
cover of the lubricating oil pump and is driven
See turbocharger instruction book, section 512. through this pump.

If the pre-set tripping speed is exceeded, the spring-

Regulating Shaft loaded flyweight (1), see fig. 1, will move outwards
and press down the arm (2).
The governor movements are transmitted through a
spring-loaded pull rod to the fuel pump regulating The arm is locked in its bottom position by the lock
shaft which is fitted along the engine. pin (3) which is pressed in by the spring (4).

The spring-loaded pull rod permits the governor to At the same time the arm (2) presses down the
08028-0D/H5250/94.08.12

give full deflection even if the stop cylinder of the spindle (5), and the pneumatic valve (6) opens,
manoeuvring system keeps the fuel pump regulating whereby compressed air will be led to the Lambda
shaft at "no fuel" position. cylinder, see description 509.10, in which the piston
is pressed forward and, through the arm, turns the
Each fuel pump is connected to the common, lon- fuel pump regulating rod to STOP position, thereby
gitudinal regulating shaft by means of a two-piece, the engine stops, the spring-loaded pull rod con-
spring-loaded arm. nection to the governor being compressed.

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 MAN Diesel

509.01 Description
Edition 01H
Control and Safety Systems Page 2 (2)

L23/30H
The engine can be stopped manually by pressing
down the button (7), see fig. 1, which will activate the
spring-loaded fly weight (1) through the lever (8).

If the overspeed has been activated the overspeed

must be reset before the engine can be started.
Reset is done by means of the button (10).

The overspeed alarm (SAH 81) is activated by means

of the micro switch (9).

3 8
1

2 5

1
1. Flyweight
2. Arm
3. Lock pin
9
4. Spring
5. Spindle
6. Pneumatic valve
Normal Overspeed
poisition activated 7. Button
8. Lever
9. micro switch
10. Button
2 5 3 4 10 10

Fig 1. Mechanical overspeed (SSH 81).

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 MAN Diesel

Description 509.05
Page 1 (3) Instruments and Automatics Edition 01H

L23/30H
Main Instrument Panel

As standard the engine is equipped with an instru- The instrument panel is mounted flexibly on rubber
ment panel, comprising instruments for visual indi- elements and all manometer connections are con-
cation of the most essential pressures. nected to the panel by means of flexible hoses, as
Illustrated on fig. 1. shown on fig. 2.

Flexible hose

Rubber element

Valves

Push button

On the engine is as standard mounted an instrument

panel.

The following incorporating pressure gauges for the most Fig. 2. Cross section of instrument panel
essential pressures.
08028-0D/H5250/94.08.12

Pressure gauge for:

The connecting pipes to the manometers are equip-
PI 01 LT fresh water, inlet to air cooler
PI 10 HT fresh water, inlet engine ped with valves which make it possible to replace
PI 21/22 Lubricating oil, inlet/outlet to filter the manometers during operation.
PI 23 Lub. oil, inlet to turbocharger
PI 31 Charge air, outlet from cooler
PI 40 Fuel oil, inlet to engine

Fig. 1. Lay-out of instrument panel

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 MAN Diesel

509.05 Description
Edition 01H
Instruments and Automatics Page 2 (3)

L23/30H
Instrumentation - too high press. drop across lub. oil filter
- too high HT FW temperature - outlet engine
As standard the engine is supplied with the following - too low starting air pressure - inlet engine
instrumentation mounted local on the engine: - too high engine speed (overspeed)

Thermometer TI 01 LT water - inlet air cooler The actual number and type of the alarm- and shut-
Thermometer TI 02 LT water - outlet from air cooler down switches for the plant can be seen in the list
Thermometer TI 03 LT water - outlet from lub. oil cooler "Engine Automatic part list" in this section.
Thermometer TI 10 HT fresh water - inlet to engine
Thermometer TI 11 HT fresh water - outlet each cylinder
Thermometer TI 20 Lubricating oil - inlet to cooler Leakage Alarm (LAH 42)
Thermometer TI 22 Lubricating oil - outlet from filter
Thermometer TI 30 Charge air - inlet to cooler Waste and leak oil from the comparement, for the
Thermometer TI 31 Charge air - outlet from cooler injection equipment, fuel valves, high-pressure pipes
Thermometer TI 40 Fuel oil - inlet to engine and engine feed pump (if mounted) is led to a fuel
Thermometer TI 60 Exhaust gas - outlet each cylinder leakage alarm unit.
Thermometer TI 61 Exhaust gas - outlet turbocharger

The actual number of the instrumentation for the

plant can be seen on the diagrams for the specific Normal leakage
plant in the sections 512-513-514-515-516.
C
For code identification see 500.20.

Pressostates and Thermostates B

Leak alarm
Normal level
The engine is supplied with a number of alarm- and
shut-down functions. The alarms shall via the alarm
panel worn against an abnormal working condition,
which can lead to break down and the shut-down
functions shall stop the engine before a break down.
I.e. a shut-down is "worse" than an alarm because A
a shut-down is given if the engine could be severe
damage by running on these conditions.
High level
As standard the engine is equipped with:

Shut-down Switches for

Leakoil
- too low lubricating oil pressure - inlet engine
08028-0D/H5250/94.08.12

Alarm
- too high HT FW temperature - outlet engine Normal
- too high engine speed (over speed)

Alarm Switches for

- leaking fuel oil

- too low lubricating oil pressure - inlet engine
- too low prelubricating oil pressure (level
Waste oil outlet
alarm)

Fig. 4. Fuel oil leakage alarm.

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 MAN Diesel

Description 509.05
Page 3 (3) Instruments and Automatics Edition 01H

L23/30H
The alarm unit consists of a box with a float switch Alarm for Prelubricating (LAL 25)
for level monitoring, see fig. 4.
Alarm for missing prelubricating, when the engine
The supply fuel oil to the engine is led through the is stopped is given by means of a level switch (LAL
unit in order to keep heated up, thereby ensuring 25) mounted in the main lubricating oil pipe.
free drainage passage even for high-viscous wa-
ste/leak oil.
Alarm and Shut-down for Overspeed
Under normal conditions there will always be a smal-
ler amount of waste/leak oil from the comparement, When the mechanical overspeed is activated, see
this will be led out through the bore "A" in the pipe 509.01 fig. 2, a micro-switch will release the alarm
"B" as illustrated. for overspeed (SAH 81) and activate the shut-down
solenoid in the governor.
In case of a larger than normal leakage, the level
in the box will rise and the level switch "C" will be The latter function is a back-up for the mechanical
activated. The larger amount of leak oil will be lead overspeed.
out through the top of the pipe "B".
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 MAN Diesel

Description
Lambda Controller 509.10
Page 1 (2)
Edition 09H

L23/30H

Purpose Thus the solenoid valve (4) opens. The jet system is
activated, the turbocharger accelerates and increases
The purpose with the lambda controller is to prevent the charge air pressure, thereby pressing the piston
injection of more fuel in the combustion chamber than (3) backwards in the lambda cylinder (5). When the
can be burned during a momentary load in-crease. lambda ratio is satisfactory, the jet system will be
This is carried out by controlling the relation between de-activated.
the fuel index and the charge air pressure.
At a 50% load change the system will be activated
The Lambda controller is also used as stop cylin- for about 3-8 seconds.
der.
If the system is activated more than 10 seconds,
the solenoid valve will be shut off and there will be
Advantages a remote signal for "jet system failure".

The lambda controller has the following advan-

tages: Fuel oil limiting during start procedure

- Reduction of visible smoke in case of sud- During the start procedure the lambda controller is
den momentary load increases. used as an index limiter.

- Improved load ability. Hereby heavy smoke formation is prevented during

start procedure and further the regulating device
- Less fouling of the engine's exhaust gas cannot over-react.
ways.

- Limitation of fuel oil index during starting Air Consumption

procedure.
At 50% step load the air consumption will be as
follows:
Principles for functioning

Figure 1 illustrates the controller's operation mode. Cyl. no. 5 6 7 8

In case of a momentary load increase, the regulat-
ing device will increase the index on the injection Nm3 0.70 0.84 0.98 1.12
pumps and hereby the regulator arm (1) is turned,
the switch (2) will touch the piston arm (3) and be
pushed downwards, whereby the electrical circuit
will be closed.
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 MAN Diesel

509.10 Lambda Controller Description

Page 2 (2)
Edition 09H

L23/30H

1. Regulating arm
2. Switch (Pick-up)
3. Piston
4. Solenoid valve
5. Lambda controller
6. Overspeed device
(mecanical activated 3/2 valve)

5 Charge air
receiver

3
2
1
~
4 Engine's
compression
air system

Fig 1 Lambda controller incl. start limitation

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 MAN Diesel

Description
Starting Box 509.35
Page 1 (1) Edition 02

L23/30H
Description Engine / Turbocharger RPM

The starting box is mounted on the engine's control Engine RPM and T/C RPM a
? re indicated on Starting Box
side. On front of the box there are the following in-
dications/pushbuttons:

– Indication of engine and turbocharger RPM

– Indication of electronic overspeed
– Pushbutton for "Manual Start"
– Pushbutton for "Manual Stop" External Indications
– Pushbutton for "Remote" *
– Pushbutton for "Local" * There are output signals for engine RPM and tur-
– Pushbutton for "Blocking" * bocharger RPM.
Engine: 0 - 1200 RPM ~ 4-20 mA
TC: 0 - 60000 RPM ~ 4-20 mA

* The function chosen is indicated in the pushbutton. The pushbuttons for "Remote", "Local" and "Blocking"
See fig. 1. have potential free switches for external indication.

Manual Start All components in the starting box are wired to the
built-on terminal box.
The engine can be started by means of the start
button, but only if the button "Local" is activated.

The manual, local start is an electrical, pneumatic

start, i.e. when activating the start button a solenoid
valve opens for air to the air starter, thereby engaging
the starter and starting the diesel engine.Throughout
the starting cycle the start button must be activated.

The air starter is automatically disengaged when the

diesel engine exceeds 110 RPM. If the start button is
disengaged before the diesel engine has exceeded
110 RPM, further starting cycles are blocked, until
5 sec. after the engine is at standstill.

Remote Start

Remote start can only take place if the pushbutton

for "Remote" is activated.

Manual Stop

The "Manual Stop" button is connected to the stop

coil on the governor.

Blocking

If "Blocking" is activated, it is not possible to start

the diesel engine.
Fig 1 Starting box.

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 MAN Diesel

Description 509.40
Page 1 (1) Converter for Engine- and Turbocharger RPM Signal Edition 10D

L23/30H
Engine RPM signal The "engine run" signals will be given through a relay.
One for synchronizing and one for start/stop of pre.
For measuring the engine's RPM, a pick-up mounted lub. oil pump or alarm blocking at start/stop.
on the engine is used giving a frequency depending
on the RPM. To be able to show the engine's RPM
on an digital tachometer, the frequency signal is Safe start
sent through an Speed Measuring & Loop Fail Monitor
where the signal is transformed into a proportional When the safe start signal is activated the engine
4-20 mA ~ 0-1000 or 1200 RPM signal. can start. When the engine reach 140 RPM the air
starter will be shut-off.
Further, the Speed MeasuringL & L
L oopLL Fail Monitor
has following signals;: Further, the safe start signal is a blocking function
- overspeed for the air starter during rotation.
- engine run
- safe start
- tacho fail Tacho fail

The tacho fail signal will be on when everything

is normal. If the pick-up or the Monitoring fails the
signal will be deactivated. E.g. if there is power
supply failure.

The Speed Measuring & Loop Fail Monitor for engine

RPM signal is mounted in the terminal box on the engine.

Turbocharger RPM signal

For measuring the turbocharger RPM, a pick-up

mounted on the engine is used giving a frequency
depending on the RPM. To be able to show the
turbocharger's RPM on an digital tachometer,
Fig 1. Speed Measuring & Loop Fail Monitor
the frequency signal is sent through a f/I converter
(frequency/current converter), where the signal is
Overspeed transferred into a proportional 4-20 mA ~ 0-60000
RPM and then sent through a Speed Measuring &
When the engine speed reach the setpoint for elec- LLoop Fail Monitor
tronic overspeed the Speed measuring & & & Loop Fail
Monitor gives a shutdown signal and a alarm signal The Speed Measuring & & LLoop Fail Monitor is mounted &
in the terminal box on engine.
through a relay.
08028-0D/H5250/94.08.12

Engine run

When the engine speed reach 710 RPM or 200

RPM + 10 seconds the converter gives a "engine
run" signal.

The engine run signal will be deactivated when

the speed is 640 RPM. If the engine speed haven't
been over 710 RPM the signal will be deactivated
at 200 RPM.

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 MAN Diesel

Working Card Functional Test and Adjustment of Safety, 509-01.00

Page 1 (2)
Alarm and Monitoring Equipment Edition 01H

L23/30H

Safety precautions Special tools

Stopped engine Plate No Item No Note.

Shut-off starting air
Shut-off cooling water See Related Procedure
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description

Function test and adjustment of safety, alarm and

monitoring equipment. Hand tools

See Related Procedure

Starting position

Related procedure

Overspeed trip 509-01.05

Pressostate 509-05.00
Thermostate 509-05.01
Level switch (LAL 25) 509-05.02
Analog pressure transmitter 509-05.03
Analog temperature transmitter 509-05.04

Man power Replacement and wearing parts

08028-0D/H5250/94.08.12

Working time : hours Plate No Item No Qty. /

Capacity : man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

03.32 - ES0
 MAN Diesel

509-01.00 Functional Test and Adjustment of Safety, Working Card

Edition 01H Page 2 (2)
Alarm and Monitoring Equipment

L23/30H
Maintenance of monitoring and safety sy- For check of these functions use the working cards
stems mentioned under related procedure on page 1.

One of the most important parameters in the pre-

ventive work is that the alarm system as well as the Alarm System
shutdown and overspeed devices are functioning
100%. It is important that all alarms lead to prompt investi-
gation and remedy of the error.
If some of these functions are out of operation, No alarm is insignificant. It is therefore important
they have to be repaired immediately. If this is not that all engine crew members are familiar with and
possible because of the present working situation, well trained in the use and importance of the alarm
the engine has to be under constant observation system.
until it can be stopped. The most serious alarms are equipped with slowdown
and/or shutdown functions.
It is recommended that all functions are tested every
three months according to the mentioned working
cards.

The extent of the alarm and safety functions is

vari- able from plant to plant.

08028-0D/H5250/94.08.12

03.32 - ES0
 MAN Diesel

Working Card 509-01.05

Page 1 (2) Functional Test and Adjustment of Overspeed Trip Edition 01H

L23/30H

Safety precautions: Special tools:

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water 52009 016
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Functional test and adjustment of overspeed

trip. Hand tools:

Allen key, 4 mm.

Allen key, 2 mm.

Starting position:

Functional test and adjustment of safety

alarm and monitoring equipment, 509-01.00

Related procedure:

Manpower: Replacement and wearing parts:

08028-0D/H5250/94.08.12

Working time : 1 hour Plate no Item no Qty/

Capacity : 1 man

Data:

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

96.03 - ES0S-G
 MAN Diesel

509-01.05 Working Card

Edition 01H Functional Test and Adjustment of Overspeed Trip Page 2 (2)

L23/30H
1) The engine is run up manually, (on governor Turn the engine until the adjusting screw is opposite
"synchronizer") and at no load, while watching the the opening on the side of the housing. Now loosen
tachometer. the lock screw and turn the adjusting screw, using
the tubular pin spanner supplied, see fig 2.
On reaching the revolution number indicated on
page 500.30 or in "Test Report", the overspeed trip-
ping device must function, thus actuating the stop
cylinders. The fuel injection pump control rods are
now moved to zero index, and the engine stops.

2) If the overspeed device trip at a revolution

number different from that stated on page 500.30
or in the "Test Report" the overspeed device must
be adjusted.

Fig 2.

Turn the adjusting screw outwards (slacken flyweight

spring) to reduce the revolution number. Be careful
not to screw the adjusting screw so far out that it
may touch the release arm. Tighten the lock screw
and test the overspeed device again.

4) Refit the covers when the overspeed device

functions at correct revolution number.

5) The overspeed device can be tested manually

Fig 1. by depressing the button on top af the housing, see
fig 1. This will activate the flyweight and the arm for
release of the air valve for the stop cylinders and
Adjustment of Overspeed Trip. the engine should thus stop. (This test must also be
carried out without load).
3) Remove both covers on the housing of the
08028-0D/H5250/94.08.12

overspeed tripping device, see fig 1. 6) It is recommended now and then, while the
engine is at a standstill, to move the flyweight by
means of the push button to ensure that the flyweight
can always move with sufficient ease.

96.03 - ES0S-G
 MAN Diesel

Working Card 509-05.00

Page 1 (2) Adjustment and Test of On/Off Pressostate Edition 01H

L23/30H

Safety precautions: Special tools:

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Adjustment and test of on/off pressostate. (lub.

oil,fuel oil, water etc.). Hand tools:

Screw driver.
Testing pump.
Ring and open end spanner, 10 mm.
Starting position:

Functional test and adjustment of safety

alarm and monitoring equipment, 509-01.00

Related procedure:

Manpower: Replacement and wearing parts:

08028-0D/H5250/94.08.12

Working time : 1/2 hour Plate no Item no Qty/

Capacity : 1 man

Data:

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

91.45 - ES0S-G
 MAN Diesel

509-05.00 Working Card

Edition 01H Adjustment and Test of On/Off Pressostate Page 2 (2)

L23/30H
Adjustment:

1) When the pressostate cover is removed and

locking screw pos. 5, fig 1 is loosened, the range
can be set with the spindle pos. 1 while at the same
time the scale pos. 2 is read.

1. Trial flange.
2. Drain screw.
3. Valve.
1. Range spindle.
2. Range scale.
3. Differential spindle.
4. Differential scale. Fig 2.
5. Locking screw.

4) Remove the screw pos. 2.

Fig 1.
5) Mount the testing pump on the trial flange pos.
1.
2) In pressostates having an adjustable differen-
tial, the spindle pos. 3 must be used to make the
adjusment. The differential obtained can be read Alarm for Falling Pressure:
directly on the scale pos. 4.
6) Pump up the pressure until the switch has
Set points, see page 500.30. changed. The pressure will slowly be relieved and
it must be checked that the switch change back to
the pressure stated as the alarm point.
Test:
08028-0D/H5250/94.08.12

It is possible to make a functional test of the pres- Alarm for Rising Pressure:
sure switch. This is to be carried out according to
the following procedure. 7) Pump up the pressure until the switch chang-
es, and check that it happens at the stated alarm
3) Shut off system pressure with the valve pos 3, point.
fig 2.
8) After the final check and adjustment, remove
the testing pump, mount the screw pos 2 and open
the valve pos 3.

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 MAN Diesel

Working Card 509-05.01

Page 1 (2) Adjustment and Test of On/Off Thermostate Edition 01H

L23/30H

Safety precautions: Special tools:

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Adjustment and test of on/off thermostate. (lub.

oil, fuel oil, water etc.). Hand tools:

Screw driver.
Special testing devices.

Starting position:

Functional test and adjustment of safety

alarm and monitoring equipment, 509-01.00

Related procedure:

Manpower: Replacement and wearing parts:

08028-0D/H5250/94.08.12

Working time : 1/2 hour Plate no Item no Qty/

Capacity : 1 man

Data:

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

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 MAN Diesel

509-05.01 Working Card

Edition 01H Adjustment and Test of On/Off Thermostate Page 2 (2)

L23/30H
Adjustment: Test:

1) When the thermostate cover is removed and 3) The funcional test of the thermostate is to be
locking screw pos. 5, fig 1 is loosened, the range carried out according to the following procedure.
can be set with the spindle pos. 1 while at the same
time the scale pos. 2 is read. 4) Take out the sensor of the pocket.

5) Test the sensor in a water bath, where the

temperature can be controlled.

Alarm for Falling Temperature:

6) Raise the temperature until the switch has

changed.

Then the temperature must slowly be reduced, and

check that the switch changes back at the tempera-
ture stated in the list page 500.30.

Alarm for Rising Temperature:

1. Range spindle.
2. Range scale.
7) Raise the temperature until the switch chang-
3. Differential spindle. es and check that is happens at the stated alarm
4. Differential scale. points.
5. Locking screw.
8) Adjust if necessary.

9) The sensor is mounted again.

Fig 1.

2) Thermostates having an adjustable differential,

the spindle pos. 3 can be used while the scale pos.
4 is read.

Set points, see page 500.30.

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 MAN Diesel

Working Card 509-05.02

Page 1 (2) Function and Test of Level Switch (LAL 25) Edition 01H

L23/30H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Function and test of level switch, LAL 25, in

lubricating oil system. Hand tools:

Starting position:

Functional test and adjustment of safety

alarm and monitoring equipment, 509-01.00

Related procedure:

Manpower: Replacement and wearing parts:

08028-0D/H5250/94.08.12

Working time : 1/2 hour Plate no Item no Qty/

Capacity : 1 man

Data:

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

91.03 - ES0S-G
 MAN Diesel

509-05.02 Working Card

Edition 01H Function and Test of Level Switch (LAL 25) Page 2 (2)

L23/30H

The level switch LAL 25, which is mounted on the

main lubricating oil pipe of the engine, gives alarm
for missing prelubricating oil. Vent pipe

Function.

1) By starting the prelubricating oil pump the main

lubricating oil pipe will be filled with lubricating oil,
which means that the level switch is lifted and the
alarm is disconnected.
Level switch
2) When the prelubricating is interrupted, the lub.
oil will run out of the system through the bearings, Main lubricating oil pipe
which means that level switch is lowered and the
alarm starts.
Fig 1.

Test:

The test is carried out when the engine is stop-

ped.

3) Start the lubricating oil pump, and let the pump

run about 5 min.

4) Stop the prelubricating oil pump. The alarm

must be released after 0 - 5 min., depending of the
oil viscosity.

08028-0D/H5250/94.08.12

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 MAN Diesel

Working Card 509-05.03

Page 1 (2) Adjustment and Test of Analogous Pressure Transmitter Edition 01H

L23/30H

Safety precautions: Special tools:

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Adjustment and test of analogous pressure

transmitter. Hand tools:

Ring and open end spanner, 10 mm.

Testing pump.

Starting position:

Functional test and adjustment of safety

alarm and monitoring equipment, 509-01.00

Related procedure:

Manpower: Replacement and wearing parts:

08028-0D/H5250/94.08.12

Working time : 1/2 hour Plate no Item no Qty/

Capacity : 1 man

Data:

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

91.45 - ES0S-G
 MAN Diesel

509-05.03 Working Card

Edition 01H Adjustment and Test of Analogous Pressure Transmitter Page 2 (2)

L23/30H

The pressure transmitter registers the actual pres- Adjustment:

sure and marks the change to an electrical signal,
which adjusts the pressure. 1) The pressure transmitter shall not be adjust-
ed, but the alarm limit must be set on the alarm
plant. Kindly see the instruction book for the alarm
plant.

Set points, see page 500.30.

Test:

2) It is possible to make a functional test of the

pressure transmitter. This is carried out according
to the following procedure:

3) Shut off system pressure with the valve pos.

3.

4) Remove the screw pos. 2.

5) Mount the testing apparatus on the trial flange

pos. 1. and pump on a pressure within the working
area of the transmitter.

1. Trial flange. If the alarm plant has an instrument unit, the pres-
2. Drain screw. sure can be read on this. Other wise the test can
3. Valve. be carried out by watching if the alarm plant gives
any alarm, when the alarm limit which is stated
on page 500.30 is exceeded (if the alarm plant is
adjusted).
Fig 1.

6) The screw pos. 2 is mounted, and the valve

pos. 3. is opened after the test is finished.
08028-0D/H5250/94.08.12

91.45 - ES0S-G
 MAN Diesel

Working Card Adjustment and Test of 509-05.04

Page 1 (2)
Analogous Temperature Transmitter Edition 01H

L23/30H

Safety precautions: Special tools:

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Adjustment and test of analogous temperature

transmitter, (PT 100 sensor). Hand tools:

Special testing devices.

Starting position:

Functional test and adjustment of safety

alarm and monitoring equipment, 509-01.00

Related procedure:

Mampower: Replacement and wearing parts:

08028-0D/H5250/94.08.12

Working time : 1/2 hour Plate no Item no Qty/

Capacity : 1 man

Data:

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

96.26 - ES0S-G
 MAN Diesel

509-05.04 Adjustment and Test of Working Card

Page 2 (2)
Edition 01H Analogous Temperature Transmitter

L23/30H
The PT 100 sensor consists of a resistance wire Otherwise the test can be carried out by watching
which changes resistance depending on the tem- if the alarm plant gives any alarm, when the alarm
perature. limit which is stated on page 500.30 is exceeded
(if the alarm plant is adjusted).
Look and design varify depending on the place of
measurement and manufacture. 5) The sensor is mounted again.

Adjustment:

1) The PT 100 sensor cannot be adjusted, but

the alarm limit must be set on the alarm plant.

Set point, see page 500.30.

Test:

2) The functional trial of the PT 100 sensor can be

carried out according to the following procedure.

3) Take out the sensor of the pocket.

4) Test the sensor by diving the sensor in the

water. Compare the signal from the sensor with the
water temperature.

If the alarm plant has an instrument unit, the tempe- Fig 1.

rature can be read on this.

08028-0D/H5250/94.08.12

96.26 - ES0S-G
 MAN Diesel

Working Card
Lambda Controller 509-10.00
Page 1 (3) Edition 13H

L23/30H

Safety precautions Special tools

Stopped engine Plate no Item no Note

Shut off starting air
Shut off cooling water
Shut off fuel oil
Shut off cooling oil
Stopped lub. oil circul.

Description Hand tools

Adjustment of lambda controller. Adjustable spanner 10"-12"

Starting position

Related procedure

Manpower Replacement and wearing parts

08028-0D/H5250/94.08.12

Working time : 1 hour Plate no Item no Qty /

Capacity : 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

03.13 - ES0
 MAN Diesel

509-10.00 Working Card

Edition 13H
Lambda Controller Page 2 (3)

L23/30H

Adjustment of the Lambda Controller

All adjustments are made when the engine is in

standstill position.

1) Check that the free space between the pick-

up and the band steel on the regulating arm
is min. 1 mm, see fig 1.

1. Band steel
1 2. Pick-up
3. Regulating arm
Min 1 mm free space

Fig 3 Lambda Controller

across pick-up

3
2) Turn the lever (fig 2) of the governor a few
2 times to full load with an adjustable spanner
(spring between governor and fuel rack full
com-pressed). Check that the fuel index is 17
Fig 1 Check of free space at the fuel pump.

3) In case of large deviation from index 17 ad-

justment is done by turning the regulating arm
(4), fig 3. Finally adjustment is done at the
adjustment screw (3), fig 3.

4) Adjustment completed.
08028-0D/H5250/94.08.12

Adjustment of the Stop Screw

5) Remove pipe for charge air pressure.

6) Supply air pressure until the piston rod reaches

its upper position.

7) Turn the lever (fig 2) of the governor to full load

with an adjustable spanner. Adjust the stop
screw (fig 2) to 110 % load (stationary 100%)
Fig 2 Adjustment of the stop screw according to the test bed, plus 1.5 index.

03.13 - ES0
 MAN Diesel

Working Card
Lambda Controller 509-10.00
Page 3 (3) Edition 13H

L23/30H

Use the index arm on the fuel injection pump Note : In case of start failure due to wear of the fuel
nearest to the lambda controller as the control pump, the start index must be raised to a higher level
for the index. by turning the self-locking nut anticlockwise.

8) Adjustment completed.

Adjustment of Start Index, only if mounted

After adjustment of the lambda index the start index

must be adjusted.

Force the piston by the screw on the back, see fig 4.

Check that the index is 18 mm. Adjustment is made
on the self-locking nut on the back of the lambda
controller, see fig 4.

Fig 4 Adjustment of start index

08028-0D/H5250/94.08.12

03.13 - ES0
 MAN Diesel

Plate
Page 1 (2) Overspeed Device 50903-02H

L23/30H

010
022
034
046
058
071
083
105
095 117
129
130
142

178 154
191 166, 524
201
237 500 213
536
225

262
249
274
250

333
286
345 369
298
357
370
404 382
428 394
416
441

453

465
08028-0D/H5250/94.08.12

477

512 489

490

11.02 - ES0
 MAN Diesel

Plate
50903-02H Overspeed Device Page 2 (2)

L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

010 1/E Socket Muffe 345 1/E Spring Fjeder

022 1/E Button Knap 357 1/E Button Knap

034 1/E Spring pin Fjederstift 369 1/E Nipple Nippel

046 1/E Spring Fjeder 370 1/E Spindle Spindel

058 4/E Screw Skrue 382 1/E Spring (left) Fjeder (venstre)

071 1/E Screw Skrue 394 1/E Spindle Spindel

083 1/E Cover Dæksel 404 2/E Washer Skive

095 1/E Spindle Spindel 416 2/E Screw Skrue

105 1/E Spring pin Fjederstift 428 1/E Ball bearing Kugleleje

117 1/E Cylindrical pin Cylindrisk stift 441 1/E Elastic coupling Elastisk kobling

129 1/E Lever Arm 453 1/E Spring (right) Fjeder (højre)

130 1/E Screw Skrue 465 1/E Valve attachment Ventilholder

142 1/E Flyweight housing Hus for svingvægt 477 4/E Screw Skrue

154 1/E Adjusting screw Justeringsskrue 489 1/E Pneumatic valve Pneumatisk ventil

166 1/E Spring Fjeder 490 1/E Silencer Lyddæmper

720/750 rpm 720/750 rpm
500 1/E Overspeed device, Overspeed anordning,
178 1/E Circlip Sikringsring complete, komplet,
720/750 rpm 720/750 rpm
191 1/E Flyweight Svingvægt
512 1/E Spare parts kit for Reservedelskit for
201 1/E Key Not item 489 item 489

213 1/E Ball bearing Kugleleje 524 1/E Spring Fjeder

900 rpm 900 rpm
225 1/E Housing Hus
536 1/E Overspeed device, Overspeed anordning,
237 1/E Cover Dæksel complete, komplet,
900 rpm 900 rpm
249 4/E Washer Skive

250 4/E Screw Skrue

262 1/E Pin Stift

274 1/E Lever Arm

286 1/E Nut Møtrik

08028-0D/H5250/94.08.12

298 1/E Gasket Pakning

333 1/E Spindle Spindel

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

11.02 - ES0
 MAN Diesel

Plate
Page 1 (2) Instrument Panel 50905-10D

L23/30H
08028-0D/H5250/94.08.12

PI 01 LT fresh water, inlet to air cooler

PI 10 HT fresh water, inlet engine
PI 21/22 Lubricating oil, inlet/outlet to filter
PI 23 Lub. oil, inlet to turbocharger
PI 31 Charge air, outlet from cooler
PI 40 Fuel oil, inlet to engine

00.21 - ES0
 MAN Diesel

Plate
50905-12H Instrument Panel Page 2 (2)

L23/30H
Item Item
No Qty. Designation Benævnelse No Qty. Designation Benævnelse

01 1/E Housing for Hus for 23 1/E Damper (charging air) Dæmper (ladeluft)
instrument panel instrument panel
43 4/E Screw Skrue
02 1/E Bracket for Konsol for
instrument panel instrument panel 44 4/E Serrated lock washer Stjernefjederskive

03 4/E Rubber clutch Gummikobling 45 2/E Screw Skrue

04 8/E Nut Møtrik 46 2/E Serrated lock washer Stjernefjederskive

05 8/E Spring lock Fjederskive 47 8/E Screw Skrue

06 2/E Pressure gauge Manometer 48 1/E Side plate Sideplade

0-3 bar 0-3 bar
(PI 31 and PI 23) (PI 31 og PI 23) 49 1/E Instrument panel, Instrument panel,
complete komplet
07 4/E Pressure gauge Manometer
0-6 bar 0-3 bar
(PI 01, PI 10, PI 50, (PI 01, PI 10,
PI 21-22) PI 21-22)

08 1/E Pressure gauge Manometer

0-16 bar (PI 40) 0-16 bar (PI 40)

09 7/E Needle valve Nåleventil

10 1/E 3-way valve for 3-vejsventil for

PI 21-22 PI 21-22

11 1/E Washer Skive

12 1/E Pipe Rør

13 1/E Angle union Vinkelforskruning

14 2/E Straight union Ligeforskruning

15 2/E Pressure gauge hose Manometer slange

195 mm 195 mm

16 2/E Pressure gauge hose Manometer slange

140 mm 140 mm

17 2/E Pressure gauge hose Manometer slange

300 mm 300 mm

18 1/E Pressure gauge hose Manometer slange

340 mm 340 mm

19 7/E Packing ring Pakningsring

20 2/E Reduction Reduktion

08028-0D/H5250/94.08.12

21 1/E Damper (fuel oil) Dæmper (fuel oil)

22 2/E Coupling for mano- Kobling for

meter manometer

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

00.21 - ES0
 MAN Diesel

Plate
Page 1 (3) Thermometer 50907-09H

L23/30H

Scale Length Item

Fig. Code
°F °C L L1 No.

40-240 0-120 110 100 TI 01 252

TI 02

TI 31

40-240 0-120 110 63 TI 22 264

L
TI 20

40-600 0-300 150 100 TI 30 276

L1
40-400 0-200 110 40 TI 40 288

40-220 0-120 110 100 TI 03 311

TI 10

TI 11
L
08028-0D/H5250/94.08.12

L1

04.11 - ES0
 MAN Diesel

Plate
50907-09H Thermometer Page 2 (3)

L23/30H

Scale Length Item

Fig. Code
°F °C L L1 No.

100-
1300 50-650 100 115 TI 60 323

°C°F

L1

L1

Pocket 115 335

100-
1300 50-650 65 215 TI 61 347

° C° F
08028-0D/H5250/94.08.12

Pocket 215 359

04.11 - ES0
 MAN Diesel

Plate
Page 3 (3) Thermometer 50907-09H

L23/30H
Scale Length Item
Fig. Code
°F °C L L1 No.

120-1200 50-650 140 215 TI 61 360

TI 62

Thermo-
meter 372

Feeler
NiCr-Ni 384

Pocket 100 396

120-1200 50-650 165 115 TI 60 406

120-1200 50-650 190 115 TI 60 418

Feeler
NiCr-Ni 431
08028-0D/H5250/94.08.12

Thermo-
meter 443

Pocket 200 455

04.11 - ES0
 MAN Diesel

Plate
Page 1 (2) Instruments 50907-10D

L23/30H

Fig. and Description Range Code L Item No.

0-8 bar PSL 22 012

PAL 10
PAL 22

6-18 bar PAL 70 024

0-8 bar

Pressostate

20-60°C TAL 10 2m 061

5m 073

50-100°C 2m 085
5m 097
8m 107

70-120°C TAH 12 2m 119

TSH 12 5m 120
TAH 22 8m 132
L TSH 22

Thermostate

0.2-2.5 bar PDAH 21-22 144

PDAH 43-40
08028-0D/H5250/94.08.12

Difference Pressostate

07.45 - ES0
 MAN Diesel

Plate
50907-10D Instruments Page 2 (2)

L23/30H

Fig. and Description Range Code L Item No.

0-4 bar PT 31 156

0-6 bar PT 10 168

0-6 bar PT 22 181

0-16 bar PT 40

0-16 bar PT 70 203

Pressure Transmitter

Needle Valve with 3/8" pipe thread 239

Needle valve with 1/2" pipe thread 240

Needle Valve

1-10 bar PAL 40 048

08028-0D/H5250/94.08.12

Pressostate

07.45 - ES0
 MAN Diesel

Plate
Page 1 (1) Pick-up 50908-10D

L23/30H

Length Item
Fig. Range Code
L mm no
M14xP1
Working temp. SE 90 018
-25°C - 70°C
60

0 - 1 kHz 55 SE 89 031

Pick-up
08028-0D/H5250/94.08.12

101 SE 90-3 043

75
2.7

19

07.48 - ES0
 MAN Diesel

Plate
Page 1 (2) Lambda Controller 50910-02H

L23/30H
08028-0D/H5250/94.08.12

97.14 - ES0S
 MAN Diesel

Plate
50910-02H Lambda Controller Page 2 (2)

L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

019 1/E Regulating arm, Reguleringsarm,

complete komplet

020 1/E Pick-up, Pick-up,

incl. sleeve incl. afstandsring

032 1/E Lambda cylinder, Lambdacylinder,

complete komplet

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

97.14 - ES0S
 MAN Diesel

Plate
Page 1 (2) Prelubricating Oil Alarm (LAL 25) 50919-01H

L23/30H

018

031

043

Switch point

055
08028-0D/H5250/94.08.12

07.11 - ES0
 MAN Diesel

Plate
50919-01H Prelubricating Oil Alarm (LAL 25) Page 2 (2)

L23/30H

Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

018 1/E Plug screw Propskrue

031 1/E Packing ring Pakningsring

043 1/E Loctite 577 Loctite 577

055 1/E Level switch Niveauafbryder

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

07.11 - ES0
 MAN Diesel

Plate
Page 1 (2) Level Switch in Oil Sump (LAL/LAH 28) 50920-13H

L23/30H

777
491
501
981 430
513

525 579

789

442
549
580

789 549

454

501
08028-0D/H5250/94.08.12

07.18 - ES0
 MAN Diesel

Plate
50920-13H Level Switch in Oil Sump (LAL/LAH 28) Page 2 (2)

L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

430 4/E Nut Møtrik

442 1/E Pipe for level Rør for niveau-

switch alarm

454 1/E Box for level Box for

alarm level alarm

491 2/E Red. adaptor Red. adapter

501 4/E Screw Skrue

513 1/E Plate Plade

525 1/E Gasket Pakning

549 2/E Level switch Niveaualarm

579 1/E Pipe for level Rør for niveau-

switch alarm

580 2/E Red. adaptor Red. adaptor

777 1/E Dipstick, complete Pejlestok, komplet

789 /I Loctite 577 Loctite 577

968 1/E Level switch, Level switch,

complete komplet

981 1/E O-ring O-ring

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Qty./E = Antal/Motor
Qty./I = Qty./Individual Qty./I = Antal/Individuel

07.18 - ES0
 MAN Diesel

Plate
Page 1 (2) Fuel Oil Leakage Alarm (LAH 42) 50925-08H

L23/30H

035 023
059

047

060

072

084
08028-0D/H5250/94.08.12

096 106

07.18 - ES0
 MAN Diesel

Plate
50925-08H Fuel Oil Leakage Alarm (LAH 42) Page 2 (2)

L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

023 1/E Plug screw Propskrue

035 1/E Packing ring Tætningsring

047 1/E Level switch Niveaukontakt

059 1/E Plug screw Propskrue

060 1/E Packing ring Tætningsring

072 1/E Fuel oil leakage alarm, Brændolie lækage-

complete (DIN) alarm, komplet (DIN)

084 1/E Fuel oil leakage alarm, Brændolie lækage-

complete (JIS) alarm, komplet (JIS)

096 1/E Instruction plate Instruktionsplade

106 2/E Screw Skrue

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Qty./E = Antal/Motor

07.18 - ES0
 MAN Diesel

Plate
Page 1 (2) Local Starting Box - No 2 50935-10D

L23/30H

07.45 - ES0
 MAN Diesel

Plate
50935-10D Local Starting Box - No 2 Page 2 (2)

L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

017 1/E Panel Panel

029 1/E Starting box Startboks

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Enigne. Qty./E = Qty./Motor

07.45 - ES0
 MAN Diesel

Plate
Page 1 (1) Terminal Box 50936-10D

L23/30H
08028-0D/H5250/94.08.12

07.45 - ES0